HYSTER Forklift Truck Error Codes

HYSTER Forklift Trucks Fault Codes DTC list

 

AL01

Condition: traction and hoist functions not working

Cause: incomplete connection between control card and controller; traction reversing switch not connected; damaged or defective tiller card

Solution: check connections between control card and controller; use a handset to test for operation of traction reversing switch; replace control card if tiller card is damaged

 

AL02

Condition: traction and hydraulic functions not working

Cause: main contactor tips are welded closed or motor field circuit is broken

Solution: disconnect power leads at contactor and test for an open circuit; check connections between motor field and controller

 

AL4

Condition: traction and hydraulic functions not working

Cause: damaged connection to lowering valve; damaged lowering coil or lowering valve cartridge

Solution: check electrical connection between valve coil and controller; check lowering valve coil for resistance, replace if not approximately 17.7 ohms; replace lowering valve cartridge if necessary

AL5

Condition: traction and hydraulic functions not working

Cause: damaged connection to brake or brake coil damaged

Solution: check connection between electric brake and controller; check brake coil for resistance in both directions and replace if not between 27.36 and 30.24 ohms

 

AL6

Condition: traction and hydraulic functions not working

Cause: damaged connection to traction motor; traction motor armature resistance is too low; field wires are loose or damaged; motor field winding is shorted or too low

Solution: check electrical connection between traction motor, field wires, and controller; check traction motor armature for shorts; check motor field resistance and correct if not between 0.5 and 1.5 ohms; check contactor coil for resistance of 52 ohms

 

AL7

Condition: traction functions reduced below 14°F or above 167°F and not working above 194°F

Cause: controller temperature is too hot or cold; controller temperature is not calibrated correctly; controller sensor or controller itself is damaged

Solution: move truck to a warmer or cooler location; use a handset to check that controller temperature matches room temperature (if not, replace controller)

 

AL8

Condition: traction and hydraulic functions not working

Cause: over current in driven component

Solution: check main harness for damaged connections to main contactor, brake, and electric valve coils; check contactor, brake, and elec

AL66

Condition: hydraulic function not working

Cause: battery voltage is low or controller voltage calibration is incorrect

Solution: charge or replace battery; otherwise, use handset to determine the voltage read by the controller and compare it to an actual voltmeter reading; replace controller if the two readings differ by more than 1.5 volts

 

AL99

Condition: traction and hydraulic functions not working

Cause: incorrect battery selected, damaged battery, or damaged connection to batter

Solution: check that you have the right voltage for your truck, manually check the voltage of your battery, inspect it for any damage, and check its connecting crimps and cables for damage as well

 

no LEDs or LCDs on

Condition: inoperative

Cause: B+ and/or B- missing at controller, defective battery charger, or defective battery charger

Solution: make sure battery is connected, the key switch is on, and the brake override circuit is in the run position; also test your battery charger and motor controller and replace any nonworking parts

 

no LEDs or LCDs on

Condition: forklift functions as normal

Cause:  open connection between display and controller, defective display, or defective LEDs

Solution: make sure harnesses are connected at MDI and connector B on controller; test the dash display by connecting a handset to it and testing for communication; test LEDs by disconnecting them, connecting the handset, and testing the handset; replace any nonworking parts

 

no LEDs or LCDs on

Condition: forklift functions as normal

Cause:  Because this condition is similar to the last, it will take a handset to determine its cause. If the handset displays “NO COMMUNICATION,” the controller is defective.

Solution: replace controller

 

no alarm

Condition:  traction and hydraulic functions not working

Cause: improper startup sequence by jack operator

Solution: check brake switch, accelerator, steer handle, and hydraulic inputs